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COATED FABRIC AND METHOD OFMAKING SAME I Original vFiled April 14, 1920IN VEN TOR kRoselle, New Jersey,

'y same. This invention relates Patented Apr. 27, 192s.

JESSE H. MASON, OF' ROSELLE,

TION, 0F NEWARK,

NEW JERSEY, ASSIGNOR T0 DURATEX CORPORA- NEW JERSEY, A CRPORATION 0F NEWJERSEY.

COATED FABRIC AND METHOD OF MAKING SAME.

Application led April 14, 1920, Serial No. 373,956. 4Renewed October 6,i925.

To all 'whom it may concern:

Be it known that I, Jassn H. MASON, a citizen of the United States,residing at have invented certain new and useful Improvements in CoatedFabrics and Methods of Making Same of which I declare the following tobel a full, clear, and exact description.

This invention relates to improvements in coated fabrics and the methodof making more particularly to rubber-coated fabrics in which anornamental effect is roduced by embossing the rubber-coated fa ric.

- Heretofore, it has been impossible'to produce a two-color or two-toneeffect in rubber-coated fabrics except by printing on the rubber-coatedfabric any desired design in which one or more colors might be used.This method has been and is objectionable because the design thusproduced on the coated fabric has aflat appearance and looks chea Theproduct made in this manner, there ore does not appeal to the buyingpublic as a high ade material and it has not been possible 1n thismanner to simulate the effect roduced on real leather. As a rule the coored design thus printed on the vcoated fabric has a tendency to rubofi'.

One of the objects of my invention is to provideV a new type ofcoated-fabric in which an ornamental effect is produced in more than onetone or color, giving a rich and pleasing appearance to the product.

Another object of my invention is t'o` provide a rubber-'coated fabricwhich is finished in more than one tone or color so as to simulatethemulti-color effect produced in iinishing natural leather.

Another object of my invention is to pro-- vide an improved`process forproducinga multi-color effect in rubber-coated fabrics.

In Fig. 1 lof the drawing there is illus- -trated a section throughfabric coated in accordance with the processes indicated in theapplication, and

Fig. 2 is a section through a base fabric having a modified formation. l

In. general, I accomplish the objects of my mvention and avold theobjectionable features of prior methods which have been indit'ed above,by coating a fabric backing with a base coat of rubber, embossing thebase coat, and appl ing a surface coating carrying pigment, w ich may beof a different color from the base coat, so that the surface coatinglodges in the crevices formed in the :base coat by the embossingoperation, but-is rubbed oifof the high spots of the base coat. Thecoated fabric produced in accordance with my invention, in general,comprises a fabric backing having a base coat of rubber with crevicestherein in which av surface coating carrying pigment, which may be of adifferent color from the base coat, is lodged.

In carrying out my invention, I first apply to a suitable fabricbacking, such as a drill, sateen or moleskin, a base coat of rubbercomposition. This rubber composition may be any satisfactory rubberizingcompound. The particular formula does not form a part of my invention,appropriate formulae being Well known to those skilled in the rubberart, it being understood that the ingredients will vary depending uponthe character, quality and color of the coating to be produced. Thisrubber com ound may be applied to the bac-king on a ca ender orspreading machine in the manner well understood in the rubber art.

After the base coat is applied to the backing, it is embossed in theusual manner, either by passing the rubber-coated fabric betweenembossing rolls or by impressing the desired design on the base coat byembossing plates ina press. l

After the embossing operation, a soup coat or rub is applied as will bedescribed hereinafter. This rub comprises a .suitable carrier containingpigment or dye to give color to the rub. may be such as to give the ruba different color from the base coat so that the multicolor effect maybe produced by the cont-rast between the color of the rub and that ofthe base coat, as will appear more clearly hereinafter. I have securedvery desirable results by the use of two different carriers for thepigment, both of which I-wi1l describe, it being understood that eitherof these carriers may be employed. I may use as acarrier for thepigmentin the rub coat a vulcanzing varnish made up of a vegetable The pigmentused a drying 'oil 'and sulphur. For instance, I

l may make up a rub coat by adding about eight pounds of sulphur toabout twenty-fiveA gallons of boiled linseed oil and add to this thepigments or dyes necessary to give the rub coat the desired color. Theseingrcdients are intimately mixed and the mixture thinned down until itis of the proper consistency for application to the base coat. Insteadof the rub coat described above, I may use one in which rubber cement isused as the carrier for the pigment. For instance, I may dissolve rubberin a suitable rubber solvent, add the sulphur necessary forvulcanization and the pigments or dyes necessary to give the desiredcolor to the rub coat. These ingredients are intimately mixed, broughtto the proper consistency, and applied to the base coat in the mannerwhich I will describe.

The rub coat is applied to the base coat by drawing the fabric carryingthe embossed rubber base coat beneath a spreading knife while the fluidrub coat is fed in front of the spreading knife. This method of applyinga coating is well known in the art and needs no further description tobe understood by those familiar with this art. The tension of the fabricand the rate of feed of the rub coat in front of the knife is regulatedand adjusted so` that the rub coat lodges in the crevices formed in the.base coat by the embossing operation and is rubbed otf of the highspots by the spreading knife so that the base coat is exposed at thehigh spots.

After the application of the rub coat, I may, when desired, apply atransparent top coat of a clear vulcanizing varnish. For instance, I addabout eight pounds of sulphur to about twenty-five gallons of boiledlinseed oil, mix these ingredients intimately', thin to the properconsistency-and apply by a spreading knife. I use a transparent top coatin cases where the pigments are of such nature that the finished productwould otherwise be likely to crock or rub o.

The material coated as described above is then fed in the heater whereit is cured or vulcanized by exposure to heat in the manner well knownin the art. The curing operation may follow directly after theapplication of the rub coat or, in cases where a top coat is applied, itmay follow the application of the top coat.

It will appear that the material produced in accordance with the processwhich I have described is characterized by a base coat of rubber havingcrevices or depressions in which a suitable vulcanizing carrier carryingpigment is deposited, the pigment being of a dilferent or contrastingcolor from the color of the base coat, so that a two-color or two-toneeffect is obtained in this way. Since the ,final step in?, the processis the vulcanizing of all of the materials deposited on the backing,they are all amalgamated into a single compact mass so that the pigmentswill not crock or rub off. This is particularly true where they arccovered by atop coat as described.

I am aware that the particular embodiment of my invention, which I havedescribed here, is succeptible of considerable variation withoutdeparting from the spirit of my invention and, therefore, I desire toclaim the same broadly, as well as specifically, as indicated by theappended claims.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent is:

l. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, forming elevations anddepressions in the basecoat, and depositing a coating carrying coloringmatter in the depressions of the base coat while leaving the elevationssubstantially u n-y coated.

2. The process of making coated fabrics comprising applying a base coatof rubber composition Ito a suitable backing, forming elevations anddepressions in said base coat,

depositing a coating carrying coloring matter inthe depressions formed1n the base coat, and then vulcanizing the coated material, said basecoat being free from the coating exterior to said depressions.

3. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, forming elevations anddepressions in said base coat, depositing a coating carrying matter inthe depressions only formed in said base coat, applying a top coat, andvulcanizing the coated material.

4. rIhe process of making coated fabrics comprising applying a base coatof rubber compositionto a suitable backing, forming elevations anddepressions in said base coat, and depositing a coating comprising avulcanizable carrier and coloring matter in thc depressions formed insaid base coat, and then'vulcanizing the coated material, said base coatbeing free from the coating exterior to said depressions.

5. The process of making coated fabrics comprising applying a base coat.of rubber composition to a suitable backing, forming elevations anddepressions in said base coat, depositing a coating comprising avulcanizable carrier and coloring matter in thc depressions formed insaid base coat, thereby leaving the base coat exposed on the elevations,and then vulcanizing the coated material.

6. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, forming .elevations anddepressions in the said base coloring coat, depositing a coatingcomprising a vulcanizable carrier and coloring matter in the depressionsformed in said base coat, applying a transparent top coat, and thenvulcanizing the coated material, said base coat being free from thecoatngexterior to said depressions.

7. The process of making coated fabrics 7 comprising applying a basecoat of rubber elevations and depressions in the said basecoat,depositing a coating comprising a vulcanizmg varnish Ilike material andcoloring matter in the depiessions formed in the base' coat Whileleaving the elevations uncoated, and then vulcanizing the coatedmaterial.

9. The process of making coated fabrics comprising applying abase coatof rubber composition to a suitable backing, forming elevations anddepressions in the said base coat, depositing a coating comprisingboiled linseed oil, sulphur and coloring matter in said depressions, andthen vulcanizing the coated material, said base coat being-free from thecoating exterior to said depressions.

10. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, forming elevations anddepressions in the said base coat, depositing a coating comprising avarnish like material and coloring matter in the said depressions, thenapplying a top coat of vulcanizing varnish, and finally Vulcanizing thecoated material.

11. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, embossing the base coat,depositing a coating comprising a sulphur containing varnish like.material and coloringmatt'er in the depressions formed in the base coatby the embossing, applying a top coat of vulcanizing varnish, and thenvulcanizing the coated material.

12. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, embossing A the base coat,depositing a coating comprising boiled linseed oil, sulphur and coloringmatter in' the depressions onlyv formed in the base coat by theembossing, applying a top coat, and then vulcaiiizing the coatedmaterial.

13. A coated fabric comprising a suitable backing, a base coat of rubbercomposition carried 'thereby v and having depressions formed therein, acoating carrying suitable coloringfmatter deposited in said depressionsonly, and a transparent top coat, all of said coatings being vulcanized.

14. A coated fabric comprising a suitable backing, a base coat of rubberncomposition carried thereby and having depressions formedV therein, anda coating carrying coloring matter deposited in said depressions andexposing the higher portions, said coatings being vulcanized as aunitary mass. f

15. A coated fabric comprising a suitable backing, a base coat of rubbercomposition carried thereby and having depressions :formed therein, anda vulcanized coating carrying coloring-matter deposited in said fdepressions, said coatings being vulcanized' as a unitary mass, saidbase coat being free 'from the coating exterior to said depressions. A v

16. A coated fabric comprising a suitable backing, a base coat of rubbercomposition` carried thereby and having depressions formed therein, anda coating deposited in said depressions and comprising a vulcanized`carrier, sulphur and coloring matter, said coatings being vulcanized asa unitary mass, said base coat being free from the coating exterior tosaid depressions.

17. A coated fabric comprising a suitable backing, a base coat of rubbercomposition carried thereby and having depressions formed therein, and acoating deposited in said depressionswand comprising av varnisli likematerial, and suitable coloringmatter, said coatings being vulcanized asa unitary mass, said base coat being free from' the coatin exterior tosaid depressions.

18. coated fabric comprising a suitable backing, a base coat of rubbercomposition carried thereby and having depressions formed therein, and acoating said depressions and comprising boiled linseed oil, sulphur andcoloring matter, said coatings being vulcanized as a unitary mass,

said base coat being free from'the coating exterior to said depressions.

19. A coated fabric com rising a suitable backing, a base coat of rubbercomposition carried thereby and having de ressions formed therein, acoating deposite in said depressions only and comprising' varnish likematerial and suitable coloring 4matter.

carried thereby, and a transparent top coat, all of said coatings beingvulcanized.

20. A coated fabric comprising a suitable backing, a base coat of rubbercomposition carried therebyV and having depressions formed therein, anda coating carrying coloring matter lodged in said depressions andexposing the higher portions of said base coat.

21. A coated fabric comprising a suitable lll() deposited in backing, abase coat of rubber composition carried thcrebyand having depressionsformed therein, and a coating carrying suitable coloring matterdeposited in said depressions While exposing the higher portions andvulcanized to said base coat.`

22. The process of making coated fabrics comprising applying a base coatof rubber composition to a suitable backing, embossing the base coat,depositing a coating comprising a vegetable drying oil, sulphur andcoloring matter in the depressions formed in the base coat by theembossing, and then 10 vulcanizing the coated material, said base coatbeing freev from the coating exterior to said depressions.

yIn testimony whereof, I aiiix my signature.

JESSE H. MASON.

